Process for the preparation of fluorinated compounds

ABSTRACT

A subject-matter of the invention is a process for the preparation of 2,3,3,3-tetrafluoro-1-propene which comprises the following stages: (i) hydrogenation of hexafluoropropylene to give 1,1,1,2,3,3-hexafluoropropane; (ii) dehydrofluorination of the 1,1,1,2,3,3-hexafluoropropane obtained in the preceding stage to give 1,2,3,3,3-pentafluoro-1-propene; (iii) hydrogenation of the 1,2,3,3,3-pentafluoro-1-propene obtained in the preceding stage to give 1,1,1,2,3-pentafluoropropane; and (iv) dehydrofluorination of the 1,1,1,2,3-pentafluoropropane obtained in the preceding stage to give 2,3,3,3-tetrafluoro-1-propene. Stages (ii) and (iv) are carried out using a water and potassium hydroxide mixture with the potassium hydroxide representing between 58 and 86% by weight of the mixture and at a temperature of between 110 and 180° C.

FIELD OF THE INVENTION

A subject-matter of the invention is a process for the preparation offluorinated compounds, namely the fluorinated compound2,3,3,3-tetrafluoro-1-propene.

TECHNOLOGICAL BACKGROUND

Hydrofluorocarbons (HFCs) and in particular hydrofluoroolefins, such as2,3,3,3-tetrafluoro-1-propene (HFO-1234yf), are compounds known fortheir properties of refrigerants and heat-transfer fluids,extinguishers, propellants, foaming agents, blowing agents, gaseousdielectrics, polymerization medium or monomer, support fluids, agentsfor abrasives, drying agents and fluids for energy production units.Unlike CFCs and HCFCs, which are potentially dangerous to the ozonelayer, HFOs do not comprise chlorine and thus do not present a problemfor the ozone layer.

Several processes for the manufacture of 1234yf are known.

WO2008/002499 describes a process for the production of a mixture of2,3,3,3-tetrafluoro-1-propene (HFO-1234yf) and1,3,3,3-tetrafluoro-1-propene (HFO-1234ze) by pyrolysis of1,1,1,2,3-pentafluoropropane (HFC-245eb).

WO2008/002500 describes a process for production of a mixture of2,3,3,3-tetrafluoro-1-propene (HFO-1234yf) and1,3,3,3-tetrafluoro-1-propene (HFO-1234ze) by catalytic conversion of1,1,1,2,3-pentafluoropropane (HFC-245eb) over a dehydrofluorinationcatalyst.

These two abovementioned patent applications are thus targeted at theproduction of a mixture comprising a substantial portion of productHFO-1234ze.

WO2007/056194 describes the preparation of HFO-1234yf bydehydrofluorination of HFC-245eb either with potassium hydroxide,typically an aqueous solution of at most 50% by weight of KOH, or in thegas phase in the presence of a catalyst, in particular a catalyst basedon nickel, carbon or a combination of these.

The document Knunyants et al., Journal of the USSR Academy of Sciences,Chemistry Department, “Reactions of Fluoroolefins”, report 13,“Catalytic Hydrogenation of Perfluoroolefins”, 1960, clearly describesvarious chemical reactions on fluorinated compounds. This documentdescribes the substantially quantitative hydrogenation of HFP over acatalyst based on palladium supported on alumina, the temperaturechanging from 20° C. to 50° C. and then being maintained at this value.This document describes the dehydrofluorination of1,1,1,2,3,3-hexafluoropropane (HFC-236ea) by passing through asuspension of KOH in dibutyl ether, in order to produce1,2,3,3,3-pentafluoro-1-propene (HFO-1225ye) with a yield of only 60%.This document describes the hydrogenation of1,2,3,3,3-pentafluoro-1-propene (HFO-1225ye) to give1,1,1,2,3-pentafluoropropane (HFC-245eb) over a catalyst formed ofpalladium supported on alumina. During this hydrogenation, ahydrogenolysis reaction also takes place, a significant amount of1,1,1,2-tetrafluoropropane being produced. This document describes thedehydrofluorination of 1,1,1,2,3-pentafluoropropane (HFC-245eb) to give2,3,3,3-tetrafluoro-1-propene (HFO-1234yf) by passing into a suspensionof KOH powder in dibutyl ether, with a yield of only 70%. Thesereactions are described independently of one another even if it isindicated that it is possible to combine them in order to synthesize arange of ethylene, propylene and isobutylene derivatives comprisingvariable amounts of fluorine.

The document U.S. Pat. No. 5,396,000 describes the preparation of1,1,1,2,3-pentafluoropropane by catalytic dehydrofluorination of1,1,1,2,3,3-hexafluoropropane (HFC-236ea) to give1,2,3,3,3-pentafluoro-1-propene (HFO-1225ye), followed by ahydrogenation in order to produce the desired compound. Thedehydrohalogenation of HFC-236ea to give HFO-1225ye is carried out inthe gas phase, the reaction product being, in one example, conveyeddirectly to the following reactor in which the hydrogenation of thecompound HFO-1225ye to give the compound HFC-245eb takes place. It isalso indicated in this document that the compound HFC-236ea can beobtained by hydrogenation of hexafluoropropylene (HFP).

The document U.S. Pat. No. 5,679,875 describes the preparation of1,1,1,2,3-pentafluoropropane by catalytic dehydrofluorination of1,1,1,2,3,3-hexafluoropropane (HFC-236ea) to give1,2,3,3,3-pentafluoro-1-propene (HFO-1225ye), followed by hydrogenationto produce the desired compound. The reactions are carried out in thegas phase. It is also indicated in this document that the compoundHFC-236ea can be obtained by hydrogenation of hexafluoropropylene (HFP).

The document WO 2008/030440 describes the preparation of HFO-1234yf fromHFO-1225ye by reacting HFO-1225ye with hydrogen in the presence of acatalyst, in order to give HFC-245eb, and by then reacting the HFC-245ebwith a basic aqueous solution in the presence of a phase transfercatalyst and a non-aqueous and non-alcoholic solvent.

The document WO 2008/075017 illustrates the dehydrofluorination reactionof 1,1,1,2,3,3-hexafluoropropane (HFC-236ea) to give1,1,1,2,3-pentafluoropropene (HFO-1225ye) at 150° C. in the presence ofa 50% by weight aqueous KOH solution. In the absence of a phase transfercatalyst, the conversion after 3 and a half hours is 57.8% and theselectivity for HFO-1225ye is 52.4% (Test 1). In the presence of a phasetransfer catalyst, this conversion is achieved after only 2.5 hours andthe selectivity is virtually unchanged (Test 4). As indicated in Table 2of this document, it is necessary to use an organic solvent in order toincrease the selectivity for HFO-1225ye.

There exists a need for a process for the preparation of 1234yf from astarting material which is easily accessible and which results in thedesired product with a high selectivity, preferably a high yield andadvantageously a high productive output.

SUMMARY OF THE INVENTION

The invention thus provides a process for the preparation of2,3,3,3-tetrafluoro-1-propene which comprises the following stages:

-   -   (i) hydrogenation of hexafluoropropylene to give        1,1,1,2,3,3-hexafluoropropane;    -   (ii) dehydrofluorination of the 1,1,1,2,3,3-hexafluoropropane        obtained in the preceding stage to give        1,2,3,3,3-pentafluoro-1-propene using a water and potassium        hydroxide mixture with the potassium hydroxide representing        between 58 and 86% by weight of the mixture and at a temperature        of between 110 and 180° C.;    -   (iii) hydrogenation of the 1,2,3,3,3-pentafluoro-1-propene        obtained in the preceding stage to give        1,1,1,2,3-pentafluoropropane;    -   (iv) dehydrofluorination of the 1,1,1,2,3-pentafluoropropane        obtained in the preceding stage to give        2,3,3,3-tetrafluoro-1-propene using a water and potassium        hydroxide mixture with the potassium hydroxide representing        between 58 and 86% by weight of the mixture and at a temperature        of between 110 and 180° C.

According to embodiments:

-   -   the hydrogenation stages (i) and (iii) are carried out in the        same reactor, preferably with the same catalyst, a separation        stage optionally being present;    -   the hydrogenation stages (i) and/or (iii) are carried out in a        multistage reactor or in at least two reactors in series, a        separation stage optionally being present;    -   the dehydrofluorination stages (ii) and/or (iv) are carried out        in at least two reactors in series, the separation stage        optionally being present;    -   the stream from stage (i) comprising the        1,1,1,2,3,3-hexafluoropropane is conveyed directly to stage (ii)        without separation of the reactants;    -   the stream from stage (i) comprising the        1,1,1,2,3,3-hexafluoropropane is conveyed to stage (ii) after        separation of the unreacted reactants, which are optionally        recycled to stage (i);    -   the stream from stage (ii) comprising the        1,2,3,3,3-pentafluoro-1-propene is conveyed to stage (iii) after        a purification stage;    -   the stream from stage (iii) comprising the        1,1,1,2,3-pentafluoropropane is conveyed directly to stage (iv)        without separation of the reactants;    -   the stream from stage (iii) comprising the        1,1,1,2,3-pentafluoropropane is conveyed to stage (iv) after        separation of the unreacted reactants, which are optionally        recycled to stage (iii).

DETAILED DESCRIPTION OF EMBODIMENTS

The invention uses four reactions in series, the reaction products beingconveyed to the following stage, optionally after having been subjectedto a treatment, for example a separation treatment, if need be.

It is possible to provide for feeding the following stage in part withreactants not originating from the preceding stage.

In the process, the reaction stages are carried out batchwise,semi-continuously or continuously. Advantageously, the process accordingto the present invention is carried out continuously. An economicalprocess for the preparation of the compound HFO-1234yf is thus obtained,the starting material HFP being easily available commercially at a lowcost.

The hydrogenation stages are carried out conventionally for a personskilled in the art. A person skilled in the art can choose the operatingconditions in order for the reactions to be substantially quantitative.

The catalysts capable of being used in these reactions are those knownfor this purpose. Mention may in particular be made of catalysts basedon a metal from Group VIII or rhenium. This catalyst may be supported,for example on carbon, silicon carbide, alumina, aluminium fluoride andthe like, or may not be supported, such as Raney nickel. Use may bemade, as metal, of platinum or palladium, in particular palladium,advantageously supported on carbon or alumina. It is also possible tocombine this metal with another metal, such as silver, copper, gold,tellurium, zinc, chromium, molybdenum and thallium. These hydrogenationcatalysts are known.

The catalyst can be present in any appropriate form, for example theform of a fixed or fluidized bed, preferably as fixed bed. The streamdirection can be from the top downwards or from the bottom upwards. Thecatalyst bed can also comprise a specific distribution of the catalystin order to manage the flow of heat generated by the exothermicreaction. Thus, it is possible to provide gradients in density ofloading, in porosity, and the like, of the catalyst in order to regulatethe exothermicity of the reaction. For example, it is possible toprovide for the first part of the bed to comprise less catalyst, whilethe second part comprises more thereof.

It is also possible to provide stages for regeneration of the catalystin a known way.

It is also possible to provide for the use of a diluting gas, such asnitrogen, helium or argon.

The hydrogenation stages are exothermic. The reaction temperature can becontrolled using means positioned for this purpose in the reactor, ifneed be. The temperature can vary by a few tens of degrees during thereaction, the reaction (i) being more exothermic than the reaction(iii). For example, the inlet temperature can vary from 20° C. to 120°C., preferably between 50 and 100° C., and the increase in temperaturecan vary from 5° C. to 100° C.

The contact time (ratio of the catalyst volume to the total stream ofthe charge) is generally between 0.1 and 100 seconds, preferably between1 and 50 seconds and advantageously between 2 and 10 seconds.

The amount of hydrogen injected can vary within wide limits. TheH₂/charge ratio can vary within wide limits, in particular between 1(the stoichiometric amount) and 30, in particular between 1.5 and 20,advantageously between 1.1 and 3. A high ratio will result in a dilutionand thus in better management of the exothermicity of the reaction.

The stream resulting from the hydrogenation stages (i) and/or (iii) canbe conveyed directly to the following dehydrofluorination stage or canbe subjected to a separation stage in order to separate the unreactedreactants (hydrogen, HFP or HFO-1225ye) before being conveyed to thefollowing dehydrofluorination stage. After separation, the unreactedreactants can be recycled.

Preferably, the stream resulting from the hydrogenation stages (i)and/or (iii) is or are conveyed directly to the followingdehydrofluorination stage.

The hydrogenation reactions of stage (i) and/or (iii) are preferablysubstantially quantitative. They can be carried out in a multistagereactor or in at least two reactors in series, a separation stageoptionally being present.

The dehydrofluorination reactions are carried out by reacting HFC-236eaand/or HFC-245eb with a water and potassium hydroxide (KOH) mixture inwhich the potassium hydroxide is present at between 58 and 86% by weightat a temperature of between 110 and 180° C., preferably of greater than150° C. and advantageously of between 152 and 165° C.

Preferably, the potassium hydroxide is present at between 60 and 75% inweight in the water-KOH mixture.

The water and KOH mixture used can originate from hydrates of formulaKOH.xH₂O (x being between 1 and 2). Preferably, the dehydrofluorinationreactions are carried out in the presence of these potassium hydroxidehydrates in the molten state and advantageously in the absence ofsolvent and/or of phase transfer catalyst.

The 1,1,1,2,3,3-hexafluoropropane in stage (ii) and/or the1,1,1,2,3-pentafluoropropane in stage (iv) is or are converted generallyto more than 90%, preferably to more than 95% and advantageously to morethan 98%.

A diluting gas (nitrogen, helium, argon or hydrogen) can be used in thedehydrofluorination reaction.

The dehydrofluorination reaction can be carried out in any type ofreactor known to a person skilled in the art. Use may be made of astirred reactor, a static mixer or a reactive column or the HFC-236eaand/or the HFC-245eb can very simply be sparged into the water and KOHmixture in a vessel. Use may also be made of at least two reactors inseries.

The amount of KOH involved in the dehydrofluorination reactions, whenthey are carried out batchwise or semi-continuously, is such that theKOH/HFC-245eb or HFC-236ea molar ratio is between 1 and 20.

During the dehydrofluorination reactions, potassium fluoride is formedand, for reactions carried out continuously, it is preferable to removefrom the reaction medium, continuously or batchwise, all or a portion ofthe KF formed. The potassium fluoride can be separated from the reactionmedium by filtration.

During the dehydrofluorination reactions, water is formed and can alsobe removed continuously or batchwise so as to maintain the KOH contentin the water-KOH mixture within the interval described above. Removal ofwater can be carried out by evaporation.

The stream resulting from the dehydrofluorination stage (ii) comprisingthe HFO-1225ye can be conveyed directly to stage (iii). Preferably, thisstream is purified beforehand, for example by distillation.

The stream resulting from the dehydrofluorination stage (iv) comprisingthe HFO-1234yf, optionally separated from the HFC-245eb, is subjected toa stage of purification, for example by distillation.

It is possible, in the process, to provide for the hydrogenation stages(i) and (iii) to be carried out in the same reactor, preferably with thesame catalyst.

The cohydrogenation is carried out in a first reactor, the outlet streamof which comprises HFC-236ea and HFC-245eb. The outlet stream can beseparated and the HFC-236ea is conveyed to a first dehydrofluorinationreactor while the HFC-245eb is conveyed to a second dehydrofluorinationreactor. The outlet stream from the first dehydrofluorination reactorpredominantly comprises HFO-1225ye and optionally unreacted HFC-236ea.The outlet stream from the first dehydrofluorination reactor can beconveyed back to the hydrogenation reactor, thus producing the compoundHFC-245eb from this HFO-1225ye. The HFC-236ea possibly separated can berecycled to the top of this dehydrofluorination reactor.

The pressure in the various reactions can be atmospheric or lower thanor greater than this atmospheric pressure. The pressure can vary fromone reaction to another, if appropriate.

Feeding with reactants generally takes place continuously or can besequenced, if appropriate.

The reactions are carried out in one or more reactors dedicated toreactions involving halogens. Such reactors are known to a personskilled in the art and can comprise internal coatings based, forexample, on Hastelloy®, Inconel®, Monel® or fluoropolymers. The reactorcan also comprise heat exchange means, if necessary.

It should be remembered that:

-   -   the degree of conversion is the % of the starting material which        has reacted (number of moles of starting material which have        reacted/number of moles of starting material introduced);    -   the selectivity for desired product is the ratio of the number        of moles of desired product formed to the number of moles of        starting material which have reacted;    -   the yield of desired product is the ratio of the number of moles        of desired product formed to the number of moles of starting        material introduced, it being possible for the yield of desired        product also to be defined as the product of the conversion and        of the selectivity;    -   the contact time is the inverse of the space velocity WHSV;    -   the space velocity is the ratio of the flow rate by volume of        the total gas stream to the volume of the catalytic bed, under        standard temperature and pressure conditions.

EXAMPLES

The following examples illustrate the invention without limiting it.

Example 1 Hydrogenation of HFP to Give HFC-236ea

Use is made of a jacketed tubular reactor with an internal diameter of21 mm and a length of 1.2 m, with circulation of water maintained at 40°C. The reactor is charged with three catalytic beds of the typecomprising pellets of Pd supported on alumina. The three catalytic bedsdiffer in the content of the supported Pd and are arranged in increasingconcentration. The catalytic bed having the lowest Pd content is foundclosest to the inlet for the reactants.

Thus, the reactor comprises a bed of 15 cm composed of catalyst having acontent of Pd of 0.5% by weight on alumina but diluted with 5 times thevolume of silicon carbide, a bed of 10 cm composed of catalyst having acontent of Pd of 0.5% by weight on undiluted alumina and a bed of 20 cmof catalyst having a content of Pd of 2.2% by weight on alumina.

Before charging the three catalytic beds, approximately 130 cm³ ofcorundum (i.e. 37 cm) were introduced into the reactor. 80 cm³ ofcorundum (25 cm) were also introduced above the first catalytic bed.

The catalyst is activated using a stream of approximately 20 l/h ofhydrogen at 250° C. for 12 h before it is first brought into service.

The pressure is 1 bar absolute.

With an HFP flow rate of 150 g/h (1 mol/h) and a hydrogen flow rate of33.6 Sl/h (1.5 mol/h) and with complete conversion of HFP, a yield ofHFC-236ea of 95.2% is obtained.

During the reaction, a maximum temperature of 105° C. was observed forthe most dilute catalytic bed and a maximum temperature of 140° C. wasobserved for the other two catalytic beds.

Example 2 Dehydrofluorination of HFC-236ea to Give HFO-1225ye

Use is made of two vessels with a volume of 1 litre connected in series(the gas stream resulting from the first vessel is used to feed thesecond vessel) and 1000 g of water and KOH mixture in which the KOH ispresent at 80% by weight are charged to each vessel. The temperature ofthe mixture is maintained between 155 and 170° C. 165 g/h of HFC-236eaare continuously introduced for 6 hours. For complete conversion ofHFC-236ea, a yield of HFO-1225ye of 93.9% is obtained.

Example 3 Hydrogenation of HFO-1225ye to Give HFC-245eb

Use is made of the same reactor as in Example 1 but with a catalyticcharge comprising a bed of 23.5 cm of catalyst comprising 0.2% by weightof Pd on silicon carbide (SiC), a bed of 15 cm of catalyst comprising0.5% by weight of Pd supported on charcoal and a bed of 40 cm ofcatalyst comprising 2.0% by weight of Pd on charcoal. The temperature ofthe water in the jacket is maintained at approximately 85° C. Thepressure is 1 bar absolute.

For an HFO-1225ye flow rate of 128 g/h and a hydrogen flow rate of 33.6Sl/h and with complete conversion, a yield of HFC-245eb of 84% isobtained.

Example 4 Dehydrofluorination of HFC-245eb to Give HFO-1234yf

Use is made of a vessel with a volume of 1 litre comprising 1000 g of awater and KOH mixture in which the KOH is present at 75% by weight.HFC-245eb is introduced continuously into the mixture, maintained at160° C., for 2 hours with a flow rate of 138 g/h and a conversion ofHFC-245eb of 83% is obtained for a selectivity for HFO-1234yf of 100%.The pressure is 1 bar.

Example 5

Use is made of the device of Example 3 with the same catalyticcomposition, except that the stream at the outlet of the hydrogenationreactor is introduced directly into the water and KOH mixture of thedevice of Example 2 comprising, in the first reactor, 850 g of water andKOH mixture in which the KOH is present at 80% by weight and, in thesecond reactor, 637 g of the same mixture.

2.79 mol/h of hydrogen and 1.04 mol/h of HFP are introduced continuouslyinto the hydrogenation reactor for 5.1 hours and, after passing into thereactors comprising the water and KOH mixture, complete conversion ofHFP and a yield of HFO-1225ye of 92% are obtained.

Example 6

Use is made of the same device as in Example 5, except that one mol/h ofunpurified HFO-1225ye obtained in Example 5 and 1.5 mol/h of hydrogenare introduced continuously for 6.4 hours. For a conversion ofHFO-1225ye of 98%, a yield of HFO-1234yf of 96.8% is obtained.

The invention claimed is:
 1. Process for the preparation of2,3,3,3-tetrafluoro-1-propene which comprises the following stages: (i)hydrogenation of hexafluoropropylene to give1,1,1,2,3,3-hexafluoropropane; (ii) dehydrofluorination of the1,1,1,2,3,3-hexafluoropropane obtained in the preceding stage to give1,2,3,3,3-pentafluoro-1-propene using a water and potassium hydroxidemixture with the potassium hydroxide representing between 58 and 86% byweight of the mixture and at a temperature of between 110 and 180° C.;(iii) hydrogenation of the 1,2,3,3,3-pentafluoro-1-propene obtained inthe preceding stage to give 1,1,1,2,3-pentafluoropropane; (iv)dehydrofluorination of the 1,1,1,2,3-pentafluoropropane obtained in thepreceding stage to give 2,3,3,3-tetrafluoro-1-propene using a water andpotassium hydroxide mixture with the potassium hydroxide representingbetween 58 and 86% by weight of the mixture and at a temperature ofbetween 155 and 170° C.
 2. The process according to claim 1, in whichthe potassium hydroxide represents between 60 and 75% by weight of thewater-potassium hydroxide mixture of stage (ii) and/or (iv).
 3. Theprocess according to claim 1, characterized in that the stream resultingfrom stage (i) and/or stage (iii) is conveyed directly to the followingstage.
 4. The process according to claim 1, characterized in that thestream resulting from stage (ii) is subjected to a purification stagebefore being conveyed to stage (iii).
 5. The process according to claim1, characterized in that it is carried out continuously.
 6. The processaccording to claim 1, characterized in that stage (ii) and/or stage (iv)is carried out in at least two reactors in series.
 7. The processaccording to claim 1, characterized in that stage (i) and/or stage (iii)is carried out in a multistage reactor or in at least two reactors inseries.
 8. The process according to claim 1 in which stage (ii) and/orstage (iv) is carried out at a temperature of between 155 and 165° C. 9.The process according to claim 1, wherein dehydrofluorination in stage(ii) and/or stage (iv) takes place in the absence of a solvent and/or aphase transfer catalyst.
 10. The process according to claim 9, whereinconversion in stage (ii) or stage (iv) is 95% or greater.
 11. Theprocess according to claim 9, wherein conversion in stage (ii) and stage(iv) is 95% or greater.